The Continuous Improvement Manager is Forza's technical authority and custodian for continuous improvement methodology across manufacturing. The role owns the common approach to value stream mapping, A3/PDCA, root cause analysis, FMEA, standard work, visual management, problem-solving governance and benefit validation.
The role will govern a prioritised portfolio of improvement activity aligned to the Manufacturing Excellence Strategy, the maturity framework, EOS Rocks and material business risks. It will work with named process owners to establish baselines, select the right method, deliver and embed controlled change, and validate sustained operational and financial benefit.
A central purpose is capability transfer. The CI Manager will coach leaders and teams, develop graduates and practitioners through repeated real-world application, and integrate learning into MIMS/IMS, controlled standards, training and competence evidence. The role enables operational ownership; it does not replace it.
KEY RESPONSIBILITIES
- Own and continuously improve Forza's common CI methodology, governance, templates, competence standards and benefit-validation rules.
- Translate the 2031 Manufacturing Excellence vision and maturity assessment into a prioritised CI portfolio focused on the highest-value operational constraints and risks.
- Establish a clear baseline, business case, process owner, milestones and sustainment plan for each material initiative before work begins.
- Lead and facilitate complex improvement activity using appropriate methods including value stream mapping, A3, PDCA, 5 Whys, root cause analysis, FMEA, standard work, visual management, SMED, error proofing and waste reduction.
- Strengthen daily management systems so that abnormalities, priorities, ownership and action status are visible and routinely controlled by line leaders.
- Improve manufacturing flow, WIP control, labour effectiveness, space utilisation, quality at source, equipment performance and schedule stability in partnership with operational owners.
- Coach Production Managers, supervisors, employees and graduates in disciplined problem solving and improvement leadership; observe application and provide constructive assurance.
- Develop CI capability using a repeatable learning cycle: demonstrate, practise with support, repeat, teach and own.
- Provide technical direction and supervised project opportunities for graduates and other developing practitioners without allowing them to become substitute operational resource.
- Ensure every completed initiative leaves a controlled standard, SOP/OPL or method; trained and competent users; a named owner; relevant scorecard measures; and reusable organisational learning.
- Work with SHEQ/Quality, Engineering, Business Systems, People and process owners to ensure changes update relevant standards, risk controls, FMEAs/control plans, training, competence and change records.
- Audit the quality of CI methods, action effectiveness, standard adherence, benefit realisation and sustainment; intervene where improvements have not become normal work.
- Build a balanced KPI stack that evolves with maturity from lagging outcomes towards process, behavioural, capability and predictive measures.
- Maintain transparent reporting on portfolio status, risks, resource, realised benefits and maturity evidence for the Production Director and relevant leadership forums.
- Promote a culture where problems are made visible early, knowledge is organisational property, standards are constructively challenged and prevention replaces firefighting.
EXPERIENCE
- Significant experience leading continuous improvement or operational excellence activity in a manufacturing environment.
- A strong record of delivering measurable and sustained improvements in safety, quality, delivery, cost, productivity, capacity or cash.
- Experience leading cross-functional improvement projects from diagnosis and baseline through implementation, handover and benefit validation.
- Experience establishing or improving daily management, visual controls, standard work and structured problem-solving routines.
- Experience coaching operational leaders and frontline teams so that improvement capability transfers into line ownership.
- Experience of controlled change within a quality-management system; ISO 9001-aligned manufacturing experience is highly desirable.
- Experience developing graduates, CI practitioners or project teams would be advantageous.
- Experience in timber products, bespoke manufacturing or a high-mix, make-to-order environment would be helpful but is not essential.
KEY SKILLS AND QUALIFICATIONS
- Expert practical knowledge of lean manufacturing and continuous improvement methods, including VSM, A3, PDCA, 5 Whys, root cause analysis, FMEA, standard work, visual management, SMED and error proofing.
- Strong portfolio and project leadership, with the judgement to prioritise work by risk, customer impact, constraint relief, financial value, strategic dependency and readiness.
- Commercial and analytical capability: able to define baselines, interpret operational data, build benefit hypotheses and validate realised value without moving loss elsewhere.
- Confident facilitation, coaching and influencing skills across shopfloor, management and senior leadership audiences.
- Strong systems thinking and the ability to connect manufacturing, quality, engineering, planning, supply chain, people and cost across the value stream.
- Disciplined approach to governance, documented information, risk-based thinking, change control and organisational knowledge.
- Practical, visible and hands-on leadership style, with resilience, constructive challenge and strong follow-through.
- Relevant Lean, Six Sigma or continuous improvement qualification is desirable; degree-level study in engineering, manufacturing, operations or a related discipline would be advantageous.
- Competent user of standard data analysis and presentation tools; able to make complex operational information clear and actionable.
Continuous Improvement Manager in Crawley employer: Forza Doors Ltd
Forza is an exceptional employer that fosters a culture of continuous improvement and operational excellence, making it an ideal place for a Continuous Improvement Manager. With a strong emphasis on employee development, the company offers extensive coaching opportunities and a structured learning environment, ensuring that team members can grow their skills and advance their careers. Located in a dynamic manufacturing setting, Forza provides a collaborative atmosphere where innovation is encouraged, and every employee's contribution is valued, making it a rewarding workplace for those seeking meaningful impact.
